Manufacture of sheet materials



July 31, 1945. R. G. JACKSON 2,380,762

MANUFACTURE OF SHEET MATERIAL Filed March 24, 1941 Patented July 31,1945 UNITED STATE s PATENT assoas'z OFFICE.

MANUFACTURE or sham MATERIALS 12.1,. G. Jackson, Woodbury, N. J.

v Application March 24, 1941, Serial No. 385,030

9 claims... (c|. 11'I8) This invention relates to a method of andapparatus fortreating sheet material particularly of the type employedfor decorativeor other purposes, on doors. walls and other surfaces.

By means of this method and apparatus, sheet 1 material is providedwhich is of the general type described and claimed in my patents, Nos.1,729,833 and 1,798,779; also, there is provided sheet materialcharacterized by the uniform distgbution of the penetrant in the body ofthe s eet.

In applying a penetrant to a sheet material for impregnation purposes,it is frequently dimcult, particularly with a dense or fairly solidsheet,

to obtain uniform distribution of the penetrant in pores well down, inthe body of the sheet. The term fpores" is-used as the equivalent ofinterstices to indicate space in the sheet not occupied bynon-absorbent, material. For ordinary saturation purposes. for instance,a less filter whereby surface coloring of the sheet is f efiected, butlittle or no coloring into the body of the sheet.

In,the present invention, a sheet is provided with a multitude of veryfine openings constituting ducts extending from a surface into the bodyof the sheet so that a penetrant, such as a saturan-t or decorativecoloring material, applied to a surface of the sheet so treated, passesmore freely into or through the sheet. Such pin hole piercing of thesurface is preferably done by rouletting and is in contrast toperforations or any similar treatment such as requires the removal ofany substantialaniount of the material of the sheet in the making of,the openings. Although the surface of the sheet may be hard andcompactand resistant toimpregnation, after the pene trant passes beneaththe surfaces, it spreads latof a duct or pin hole opening than from theby way of illustration in the thickness of a laminated sheet in which .apenetrant;

of the sheet and the degree of lateral spread of The more dense thesheet the shorter the distance between the ducts.

Apparatus that may be employed in the present method, and certain typesof products that are prepared thereby, are shown diagrammaticallythe'accom-panying drawing, in which:

Fig. l is a vertical section of one form of appara'tus for piercing thesurface of a sheet in accordance with the method of the presentinvention; Fig. la is a vertical section of a form of.apparatus fortreating a rouletted sheet with a penetrant;

Fig. 1b is a fragment of a section of the apparatus shown in Fig. 1taken on line di -a;

Fig. 2 is a diagrammatic representation 'of a modification of theapparatus;

Fig. 3, is a fragmentary sectional view of a sheet and rouletting meansapplied thereto, the

rouletting means extending through the sheet from one side to the other;a r

Fig, 4 is a fragmentary sectional view taken on a plane parallel to andbetween the sides of a sheet, showing one arrangementof ducts ina sheet,and illustrating the. distribution ofa penetrant into the body of asheet from the sides of one of the ducts:

Fig. 5 is a fragmentary sectional view through the thickness of a sheetin which ducts extend part-of the way through the sheet;

Flg. 6 is a fragmentarysectional view through ducts extend through oneof the laminations;

Fig. 7 is a fragmentary plan view of a sheet in which relatively shortslits have been made prepared from such materials as animal, vezernormal surface of a sheet. The ducts are distributed uniformly and arespaced 9. predeterincrosssectionasshowriinFigA;

Fig. 8 is an enlarged fragmentary sectional view .as'distinct fromopenings substantially circular through the thickness of a plastic sheetin which ducts and applied penetrant extend part of the way into thebody of the sheet; and

Fig. 9 is a diagrammatic representation. of

a fragment of a floor covering showing ducts and coloring material offigured decorations extending through the thickness of, the floorcovering and showing the zoning of the different colors making up theflgured decorations.

The present method maybe applied to various types ofsheet materialsthatare impregnable, or capable of being impregnated. Fibrous sheetstable or mineral fibers with or without binders are used. .Felt,asbestos, wood, or'plper sheets,

mined distance apart depending upon the'density or sheets preparedfromcertain types of plastic 2 a,sso,':eseomposiuonseresetistectorilyemplond-TheluusiendL-duetslmuextendthroulhtheplasflcoomposltionmubeotthewpeotelinoupperlsyerlmlyorthromhhoththeluen.leumcompositlomeplestlcwoodeompositionorlhl'lmlwhichillmtntesnporoulphsticotherplnsticwithslmcientplesticbindermixedsheethsvinleheckingiendeluerotphstie withenberornnelymundnb'ertobeeslen-U ll,ductseresholm utendinlm f om deredtotormesolidthomhporoussheet.tluoulhtheplllticlqer. Theductsinsuchemestiesheetssrezenerellyoonsideredunsuitsheetmsy.ildesired.extendthmhthenhsticebletorpenetretionmirpooes. Anyplesticsheet, layerliendnlsothroluhflaebeckincluerl. whetherornot iteontninsnbemissuitablefor 'lhehorilontnilinesll'betweentheductsllillususeinthepresentproceagifltisporoumnfld 1. trl' h nmtlfldenthotpenetnflonotepenetnble with I. fluid penetrsnt used. for settrout (colored blue,- forinstnnoe) with said uretion or deearativepurposes. By peri'ontin: ductsextending port the m throuah the such a sheet, penetration is obtainablenot only sheet. In linoleum with e burlap beckini, i'orn-omanoutersurieeebutslsolaterallynnmthe instance. the eolorins msterielml! extend" wellsoteachduct. Bincepenetretionisthusobll Jninllidefleettlined.esmoothersurteoeoenbeinitisllyprovldedonesheetanddependenoeneednotbeentirelyplaced on penetration from such surface only.

The ducts in a sheet may be pin ducts, such a thoseproduoedhyroulettesorothertypesoi'hole tonninzor mechines. Ductserealsopm- Punch duoed bydrillinz, in which case some of themetu'ieloi'thesheettreetedisremoyedendtheformedbytheuseoi'averyiinedrilLsoiinethat theproductwheninuse,

plemedsheetwillpassintothebodyofthesheet throuzhtheductsendlaternllybeneeth the-m greeterthnn s tit-5m aseiinishediiooroovaointsl extendiromthemu I 'n; we of illustration, the mm mm (m. 1) a sheet I! in positionto:- pain:

adjacent ducts as at 22. Ordinarily, as in the case of a hard Krai'eltsheet, the ducts may be spaced from one-sixteenth to one-eighth of aninch apart.. The spacing of ducts as well as the viscosity of thepenetrant varies with the density or absorbency of the sheet.

A penetrant suitable for floor covering purposes may be prepared bygrinding from about two to three parts by weight of pigment to one partby weight of oil or vehicle to form a paste. The proportion of oil topigment depends upon the oil absorption of the pigment. Some pigmentsrequire more oil to wet them or to'make a paste than other pigments. Theabove paste is thinned to a suitable consistency with either oil ornaphtha in the case of oil paints, and in the case of water paints,thinning may be accomplished with water. I V

A suitable formula for a green penetrant is as follows:

' Pounds Chrome green 250 Cliffstone L 200 The above mixture is groundwith about 210 pounds boiled linseed oil, and-the resulting pastethinned down to a proper viscosity.

To produce a blue penetrant, the following formula may be used:

Pounds Ultramarine blue 250 Cliffstone 200 Lithopone 375 Cliffstone 200The latter pigments are ground in about 200 pounds of boiled oil to forma paste which is thinned to a desired consistency.

The viscosity of a penetrant, such as the above paints, may vary from toseconds on a #10 Ford viscosity cup. Such 'vis'cosities vary dependingon the amount of penetration. desired, and ,on the manner of applyingthe penetrant. The pigments and oils are also varied, both incomposition and in theirproportions.'- The pr'oportions may be' variedfor reasons other than those indicated above, namely, for the purpose ofvarying the'color obtained in a sheet.

Certain sheets tend to repel penetrants such as coloring materialsprimarily because of their moisture content. A satisfactory moisturecontent is below two or three per cent. Some papers have a higherproportion of moisture and are still usable. A "bone dry" paper isdesirable, but

I paper carrying up to or about five per cent of moisture is consideredpractical for penetration purposes with decorating or other media,

In the use of print blocks i1 and it, such as those on flat bed machinesin floor covering plants, it is not necessary that there shall be anydefinite relation between the spacing of the lines on a print block andthe spacing of the ducts in a sheet. The paint or'penetrant is depositedby the wooden lines of a block and the paint thus applied covers theentire surface of the sheets therefrom, so that when a sheet is passedbetweenthe rollers, it is pierced by the points. The points 21 are longenough to pierce a sheet through its thickness or part of the waythrough its thickness. The sheet 24, after piercing, is passed betweenrollers 28 and 29 which may be engraved rollers, or other rollers bywhich a penetrant may beapplied either to the top of the sheet or to thebottom or both. After applying the penetrant, the sheet is passedbetween calenurants, may be applied such as asphalts, tar and.

other bitumens. In the preparation of roofin sheets in which it isessential that the fibrous material employed for this purpose be filled,saturation may be accomplished quickly and thoroughly. A sheet. afterbeing pierced may be passed through asaturation tank with or withoutmeans for subjecting the saturant to pressure. Under certain conditionsplastics or thermoplastics in fluid or melted form are forced into apierced sheet. Plastic wood or a plastic made from pigment and oil maybe used for this purpose. The plastic after entrance into the ducts andpores of a sheet eventually solidifies.

For some purposes it is found desirable to maintain the upper surface ofa-floor covering, for instance, smooth and fairly dense. In such casethe backof the sheet may be pierced and ducts provided in the sheetwhich pass about threequarters or'four-fiiths of the way through thethickness of the sheet without breaking the top surface. The penetrantis then applied to the pierced side of the sheet. By this method, apenetrant of higher viscosity can be used whereby a saving of solventsor other vehicle is realized and a denser sheet is obtainable. I

In the preparation of a sheet material in ac- V cordance with thepresent invention, a sheet may be pierced before there are anyoperations on pressed into the sheet, forming an inlaid material.

In other words, the sheet forms a matrix into which a plastic materialcan be forced. A sheet to be decorated may be primed or moistened beforethe decorating material is applied. A sheet may be saturated orsurface-treated after the decoratin material is applied. It may or maynot be calendered or pressed to a smooth surface at any stage duringprocessing. The calenderingtime depends on the nature of the materialsused and thedrying time of such materials and also whether or not they,are thermoplastic.

' Ducts may be any shape in cross section. as. for instance, circular,or substantially so, as shown in Fig. 4, or they may be in the form ofslots or slits, as shown in the sheet 32 at P3 (Fiz'. 'l) Depending onthe nature of a sheet and the cross section of apiercing means, theducts w en made may be invisible to the naked eye when the goods is usedas a floor covering.

In Fig. 9 a sheet having figured decorations, hereinbefore referred to,is illustrated. Decorative figures may extend part of the way throughthe thicknessof a sheet as illustrated in Fig. 8, or all of "the waythrough the thickness of a sheet 35 as shown at 38 and 31.' The sheet 35may be a porous plastic composition provided with a backing such aswoven goods 38, or felt or other goods A linoleum or other floorcovering material may be pierced clear through from the top to thebottom of the sheet asshown at 39 to provide for penetration of thevarious colors, employed in figured decorations, through the thicknessof the sheet. Thus, an inlaid effect is produced on the top surface ofsheet goods as well as on the bottom surface of the sheet goods. Bymeans of the ducts, the inlaid effect on the bottom surface of the sheetgoods is rendered more pronounced. i

The present invention has numerous advantages in addition to thosereferred to above. Less expensive sheet material may be used to startwith and by'piercing of such sheet material, the latter is rendered moreflexible. By piercing, one may use a denser, smoother sheet which doesnot require so much filling material or top dressing in order to providea compact, smooth sheet when finished. When applying saturants,penetration is more complete. The ducts serve the purpose of permittinga sheet to be filled with harder, and better wear-resisting materialsthan the composition of the sheet itself. The sheet-acts as a skeletonwhich is filled with the wear-resisting materials. Inthe preparation ofdecorative sheets, the ducts make it possible to use a denser and hardersheet and yet make it possible to penetrate the sheet with coloringswell down into the sheet or all the way through it.

One of the difiicu'lties in the manufacture of decorative sheets is thepreparation of a solid Sheet from porous sheet materials. If there areany pores in a floor covering, for instance, after the surface is worndown from use, the worn sheet is more apt to collect dirt. A sheetprepared by the present process is readily rendered solid throughout andfree frompores. The more solid a sheet, the more satisfactory it is as awear surface.

What is claimed is:

' l. A method of manufacturing decorative impregnated sheet material,which method comprises piercing a fibrous sheet the surface of which isresistant to impregnation by fluid coloring or: toughening penetrants,said piercing providing a multiplicity of minute ducts positionedclosely together and extending uniformly across its surface withoutremoving any of the material of the sheet, and applying a fluiddecorative medium penetratingly to the surface of the sheet in certainprescribed zones to saturate the material of the sheet and extendlaterally from each duct, the ducts being so small as to be sublaterallyfrom each duct, the ducts being so small as to be substantiallyimperceptible to the eye when the goods is used as a floor covering.

3. A method of manufacturing decorative impregnated sheet material,which method comprises rouletting a sheet, the surface of which isresistant to impregnation by fiuid coloring or toughening penetrants,said rouletting providing a multiplicity of minute ducts positionedclosely together and extending well down into the body of saidsheetwhile leaving the surface sufficiently continuous to print upon,and applying a decorative saturant in figured decorations to the sheetto penetrate the sheet therewith and uniformly distribute the saturantin the body of the sheet and laterally from each duct, the ducts beingso small as to be substantially imperceptible to the eye when the goodsis used as a floor covering.

4. A method of manufacturing decorative impregnated sheet material,which method comprises piercing a fibrous-sheet, the surface of i whichis resistant to impregnation by fluid coloringor toughening penetrants,said piercing providing a multiplicity of minute ducts positionedclosely together and extending well into the body of the sheet toprovide ducts for introduction of a fiuid penetrant into the body of thesheet, the

ducts being so spaced that when said fluid penetrant is applied thepenetrant entering the ducts and spreading laterally therefrom isuniformly distributed in the body of the sheet while the surstantiallyimperceptible to the eye when the 1 goods is used as a floor covering.

' 2. A method of manufacturing decorative imregnated sheet material,which method com-' prises subjecting a sheet the surface of which isresistan to i p gnation by fluid coloring or toughening penetrants topin piercingto provide a multiplicity of minute ducts positioned closelytogether and extending well down into the body of said sheet, andapplying a decorative saturant in figured color decorations to the sheetin certain prescribed zones and poresin the material of the sheet andextend soastofillth'epinholes face of the sheet remains sufilcientlycontinuous to print upon, and applying a decorative fluid penetrant tothe sheet in certain prescribed zones to form figured decorations andcausing the penetrant to enter deep down into the ducts and laterallytherefrom to the body of the sheet, the ducts being so small as to besubstantially imperceptible to the eye when the goods is used as a floorcovering.

5. A method of manufacturing a decorative floor covering, which methodcomprises piercing a porous plastic sheet to provide a multiplicity ofminute ducts positioned closely together and extending straight intosaid sheet for the introduction of a coloring material into the body ofthe sheet, and applying a coloring medium to the surface of said sheetin the form of figured decorations, and causing said coloringmedium toextend into the body of the sheet by penetrating straight into the sheetthrough said ducts and laterally from said ducts into the pores of thesheet between the ducts to display a figured pattern at the surface ofthe sheet and to provide substantially the same pattern well downinto'the body of the sheet, the ducts being so small as to besubstantially imperceptible to the eye when the goods is used as a floorcovering.

6. A method of manufacturing a decorative floor covering, which methodcomprises piercing a porous sheet to provide a multiplicity of minuteducts positioned closely together and extending straight into said sheetfor introduction of coloring matter into the body of the sheet, andapplying coloring matter to said sheet over areas in 'the form offigured decorations simulating an multiplicity of minute ductspositioned closely to-.

gether and of relatively small cross section, and extending from asurface ofv the sheet straight into the body thereof for the passage ofcoloring matter into the body of the sheet, said sheet h'aving beenporous prior to impregnation and sufficiently smooth to print upon, saidsheet having coloring matter in said-ducts and in the pores of the sheetdisplaying figured decorations extending from one surface of the sheetwith substantially the same pattern of figured decoration well down intothe body of the sheet, the ducts being so small as to be substantiallyimperceptible to the user when the goods is used as a floor covering.

8. As an article of manufacture, a decorative covering comprising apliable sheet having a,

multiplicity of minute ducts positioned closely together and ofrelatively small cross section/extending from one surface of the sheetstraight into the body thereof and said sheet having been porous priorto impregnation and sufficiently smooth to print upon, and coloringmatter impre'gnated into the ducts and in the pores of the sheet betweenthe ducts providing an inlaid effect in apattern appearing on thesurface of the sheet and the same pattern extending well down into thebody of the sheet, the ducts being so small as to be substantiallyimperceptible to the eye when the goods is used as a floor covering.

9. As an article of manufacture, a'decorative floor covering comprisinga fibrous sheet havin a multiplicity of minute ducts positioned closelytogether and of relatively small cross section extending substantiallystraight through the thickness of the sheet and said sheet having beenporous prior to impregnation and suf'ficiently smooth ing so smallas tobe substantially imperceptible to the eye when the goods is used as afloor covering.

RALPH G. JACKSON.

